Electrokinetic dewatering of phosphatic clay suspensions
Various examples are provided for electrokinetic dewatering of e.g., phosphatic clay suspensions. In one example, among others, a system includes a separation chamber including an anode and a cathode extending ends of the separation chamber and a power supply configured to energize the anode and the cathode to establish an electric field. An inlet at one end of the separation chamber can supply a dilute feed suspension and an outlet at another end of the separation chamber can remove supernatant water. The electric field can consolidate solids in the dilute feed suspension. Consolidated solids may be removed by a removal mechanism. In another example, a method includes supplying a dilute feed suspension including suspended solids, establishing an electric field to consolidate solids, and removing supernatant water.
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This application is the 35 U.S.C. § 371 national stage application of PCT Application No. PCT/US2013/063192, filed Oct. 3, 2013, the entirety of which is hereby incorporated by reference and which also claims priority to, and the benefit of, U.S. Provisional Application having Ser. No. 61/709,402, filed Oct. 4, 2012, the entirety of which is hereby incorporated by reference.
BACKGROUNDA dilute suspension of phosphatic clays is a waste product of phosphate ore beneficiation where the mineral is separated from the ore during processing. The waste clay suspensions, which can initially contain 3-5 wt % of solids, are pumped to large impoundment areas termed clay settling areas (CSAs) for consolidation. However, increase in the solids content proceeds very slowly. In some cases, settling and self-consolidation of the clay can take 25 years to reach a solids content of 25-40 wt %. In central Florida, CSAs cover over 150 square miles, which represents 30% of the mined land.
Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
Disclosed herein are various embodiments related to electrokinetic dewatering of phosphatic clay suspensions. Reference will now be made in detail to the description of the embodiments as illustrated in the drawings, wherein like reference numbers indicate like parts throughout the several views.
Clay settling areas (CSAs) with an area of about square mile are commonly used to separate water from the solids in the slurry from a beneficiation plant. Initially, the dilute slurry can include 3-5 wt % solids, which are roughly made up of equal parts of clay, silica, and phosphate. The solids are allowed to settle for further consolidation of the solids. The addition of a flocculating agent may yield about 10 wt % of solids, but further separation can take 25 years or more. An applied electric field can greatly enhance removal of water from the phosphatic clay suspensions associated with the phosphate mining operations. Electrokinetic separation takes advantage of the charge in the suspended particles, without the use of additional materials and/or chemicals.
Referring to
At short operating times, the increase in solids content was proportional to the product of the electric field and the time over which the field was applied. Maximum solids content was reached with longer operation times and was a strong function of the electric field. The maximum increase in solids content achievable was found to be proportional to the logarithm of the electric field, which can be described by:
Δws=[(0.77 tE)−n+(7.1 log10(E)+16.5−n]−1/n
Where n is a dimensionless parameter that controls the transition from short-time to long-time behavior, E has units of V/cm, and t has units of hours. The change in solids content Δws is in reference to the initial composition of the suspension 103. Analysis showed that a solids content of about 25 wt % could be achieved in 19 hours with an electric field of 1.2 V/cm at an electrical cost of about $4/1,000 kg of clean water produced. The energy requirement for removal of water ranged from 1.25 to 175 Wh/kg water removed as a function of the electric field.
When this is translated to a one-square-mile CSA, the power requirements for increasing the solids content from about 10 wt % to about 25 wt % are on the order of 40,000 MW. At a cost of $0.10/kW-hr, the energy cost would be approximately $80 million for the water removed. By applying electrokinetic dewatering as part of a continuous or semi-continuous process, the power requirement may be reduced by dewatering over a longer period of time. The gap between the electrodes may also be reduced, allowing operation at a reduced electrode voltage while still obtaining the desired electric field.
Referring to
In the separation chamber 306, an anode 109a is positioned below a cathode 109c. For instance, the distance between the anode 109a and cathode 109c may be in the range of about 5 cm to about 10 cm, however the distance between the anode 109a and cathode 109c may varied outside of this range. In the example of
The anode 109a and cathode 109c receive DC power from a power supply 321 such as, e.g., a potentiostat. The cathode 109c may be positioned below and adjacent to the surface of the liquid (or dilute feed suspension) within the separation chamber 306, which is maintained by the position of the overflow 318 within the separation chamber 306. The anode 109a may be closely spaced below the cathode 109c to reduce the voltage levels applied between the electrodes 109 by the power supply 321. The electrodes 109 may be metallic grids such as, e.g., dimensionally stable mesh electrodes made of titanium with an iridium oxide coating or other material suitable for the environment of the EKD system 300.
Various experiments were conducted to prove the concept using the EKD system 400 of
In another experiment, a flow rate of 20 ml/min was continuously supplied from the supply tank 303 while maintaining an electric field of 2 V/cm across the electrodes 109.
Turbidity measurements were conducted on the effluent supernatant water obtained via the overflow 318 of the EKD system 400. Referring to
The settling process over a long-term period (2,000 to 6,000 minutes) is illustrated in
The pH of the supernatant water was measured and plotted in a similar manner. The pH of the phosphatic clay suspension 103 entering the separation chamber 306 was equal to 7. As shown in
The solids content of the residual clay samples removed from the separation chamber 306 after dewatering was also measured before and after every experiment. The change in solids content (Δws), presented in
A semi-continuous process such as that demonstrated by the EKD system 400 of
Referring to
Referring now to
The anode 109a should also accommodate the removal of solids. For example, a smooth sheet may be used as the anode 109a to facilitate removal of the accumulated solids. The anode 109a should also be constructed of a corrosion-resistant electro-catalytic material. For example, an iridium-oxide-coated titanium dimensionally stable electrode may be used. The cathode 109c may be made of a less expensive material, but the electro-catalytic nature of the iridium-oxide-coated titanium dimensionally stable electrode makes it appealing. The body of the separation chamber 306 and the internal components of the pumps 309 and 1109 may also be constructed of a nonconductive material to avoid unintentional ground loops.
Referring next to
It should be emphasized that the above-described embodiments of the present disclosure are merely possible examples of implementations set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.
It should be noted that ratios, concentrations, amounts, and other numerical data may be expressed herein in a range format. It is to be understood that such a range format is used for convenience and brevity, and thus, should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. To illustrate, a concentration range of “about 0.1% to about 5%” should be interpreted to include not only the explicitly recited concentration of about 0.1 wt % to about 5 wt %, but also include individual concentrations (e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.5%, 1.1%, 2.2%, 3.3%, and 4.4%) within the indicated range. The term “about” can include traditional rounding according to significant figures of numerical values. In addition, the phrase “about ‘x’ to ‘y’” includes “about ‘x’ to about ‘y’”.
Claims
1. A system for electrokinetic dewatering, comprising:
- a separation chamber including: a first side and a second side, a first end and a second end extending across the separation chamber between the first side and the second side; a bottom extending between the first side, the second side, the first end and the second end, and an anode and a cathode each having a length extending between the first end and the second end of the separation chamber, and a width extending between the first side and the second side of the separation chamber, the cathode positioned below and adjacent to a surface of a feed suspension in the separation chamber, the cathode substantially parallel to the surface of the feed suspension in the separation chamber, and the anode positioned below the cathode;
- an inlet at the first end of the separation chamber, the inlet configured to supply the feed suspension comprising solids suspended in water over a first end of the cathode at the first end of the separation chamber, wherein the inlet comprises an inlet nozzle configured to distribute the feed suspension across the width of the cathode at the first end of the separation chamber, the cathode comprising openings configured to allow the feed suspension distributed across the first end of the cathode to pass through the cathode and the solids in the feed suspension to settle in the separation chamber;
- a power supply configured to energize the anode and the cathode to establish an electric field between the anode and the cathode to consolidate the solids away from the cathode; and
- an outlet at the second end of the separation chamber, the outlet configured to remove supernatant water from the separation chamber adjacent to a second end of the cathode, the outlet comprising an overflow extending across the width of the cathode at the second end of the separation chamber, where the overflow has a horizontal opening positioned to separate and remove supernatant water over the cathode without removing fluids from the feed suspension below the cathode and consolidated solids below the cathode.
2. The system of claim 1, further comprising a second outlet at the first end of the separation chamber, the second outlet configured to remove the consolidated solids from the separation chamber.
3. The system of claim 2, further comprising a removal mechanism inside the separation chamber, wherein the removal mechanism comprises arms or ribs that move the consolidated solids toward the second outlet at the first end of the separation chamber, wherein the second outlet is below the inlet.
4. The system of claim 3, wherein the removal mechanism is a rotating scraper located adjacent to and substantially parallel with the bottom of the separation chamber, where the rotating scraper comprises a plurality of arms extending radially outward from a center point about which the rotating scraper rotates and pushes the consolidated solids to the second outlet, wherein the second outlet is in the bottom of the separation chamber.
5. The system of claim 1, further comprising:
- a pump that supplies the feed suspension to the inlet; and
- a supply tank that supplies the feed suspension to the pump, the supply tank configured to stir the feed suspension thereby maintaining the solids in the supply tank in solution.
6. The system of claim 1, wherein the feed suspension is supplied to the inlet at a constant flow rate and distributed, through an opening extending along a length of the inlet nozzle, across the width of the cathode at the first end of the separation chamber.
7. The system of claim 1, wherein the cathode comprises a dimensionally stable mesh electrode.
8. The system of claim 1, wherein the anode is positioned below and substantially parallel to the cathode.
9. The system of claim 8, wherein the anode comprises a dimensionally stable mesh electrode.
10. The system of claim 8, wherein the anode comprises a plate electrode.
11. The system of claim 1, wherein the outlet comprises a diverter configured to direct the supernatant water adjacent to the cathode from the separation chamber.
12. The system of claim 1, wherein the inlet is configured to distribute the feed suspension with a solids content of up to about 10 wt %.
13. The system of claim 1, wherein the inlet is located at a top of the first end of the separation chamber, the inlet extending between the first and second sides of the separation chamber, and the feed suspension is distributed across the width of the first end of the cathode through an opening extending along a length of the inlet nozzle.
14. The system of claim 2, wherein the second outlet comprises a sump at the first end of the separation chamber, the sump coupled to a pump.
15. The system of claim 3, wherein the anode comprises a dimensionally stable mesh electrode positioned between the cathode and the removal mechanism allowing the solids to consolidate toward the bottom of the separation chamber when the anode and cathodes are energized.
16. The system of claim 15, wherein a distance between the anode and the cathode is in a range from about 5 cm to about 10 cm.
17. A system for electrokinetic dewatering, comprising:
- a separation chamber including an anode and a cathode each extending between a first end of the separation chamber and a second end of the separation chamber;
- an inlet at the first end of the separation chamber, the inlet configured to supply a feed suspension comprising solids suspended in water to the separation chamber;
- a power supply configured to energize the anode and the cathode to establish an electric field between the anode and the cathode to consolidate the solids away from the cathode; and
- an outlet at the second end of the separation chamber, the outlet configured to remove supernatant water adjacent to the cathode from the separation chamber, wherein the outlet comprises a diverter configured to direct the supernatant water adjacent to the cathode from the separation chamber and the diverter defines a second outlet configured to direct the consolidated solids from the separation chamber.
18. The system of claim 17, wherein the cathode defines a top of the separation chamber, the anode defines a bottom of the separation chamber, and where the anode is substantially parallel to the cathode.
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Type: Grant
Filed: Oct 3, 2013
Date of Patent: Nov 26, 2019
Patent Publication Number: 20150273398
Assignee: UNIVERSITY OF FLORIDA RESEARCH FOUNDATION, INC. (Gainesville, FL)
Inventors: Mark E. Orazem (Gainesville, FL), Rui Kong (Gainesville, FL)
Primary Examiner: Salil Jain
Application Number: 14/433,163
International Classification: B01D 61/56 (20060101); B09B 3/00 (20060101); C02F 11/15 (20190101); C02F 11/00 (20060101); C02F 11/12 (20190101); B01D 21/00 (20060101); C02F 101/10 (20060101);